U.S. patent application number 13/352491 was filed with the patent office on 2013-07-18 for method and apparatus for forming fan-folded web of labels with improved registration.
The applicant listed for this patent is Jeffrey S. Morris, Neil C. Waldrop. Invention is credited to Jeffrey S. Morris, Neil C. Waldrop.
Application Number | 20130184138 13/352491 |
Document ID | / |
Family ID | 48780368 |
Filed Date | 2013-07-18 |
United States Patent
Application |
20130184138 |
Kind Code |
A1 |
Waldrop; Neil C. ; et
al. |
July 18, 2013 |
METHOD AND APPARATUS FOR FORMING FAN-FOLDED WEB OF LABELS WITH
IMPROVED REGISTRATION
Abstract
An off line apparatus for converting a rolled web into a
fan-fold web and method of fan folding a web is described. The
apparatus has a creasing station capable of receiving the web at a
feed rate. The creasing station has a first die roller, wherein the
first die roller comprises a first blade and a first cushion, and a
second die roller. A coupling mechanism synchronizes rotation of
the rollers such that the first blade engages the second cushion
and the second blade engages the first cushion during one each
rotation. A reader determines the location of a gap between the
labels. A controller receives the location of the gap from said
reader and communication with a drive mechanism to adjust the
rotation rate such that the first blade and the second cushion
engage.
Inventors: |
Waldrop; Neil C.; (Greer,
SC) ; Morris; Jeffrey S.; (Hillsboro, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Waldrop; Neil C.
Morris; Jeffrey S. |
Greer
Hillsboro |
SC
OH |
US
US |
|
|
Family ID: |
48780368 |
Appl. No.: |
13/352491 |
Filed: |
January 18, 2012 |
Current U.S.
Class: |
493/413 |
Current CPC
Class: |
B31D 1/022 20130101;
B31F 1/10 20130101 |
Class at
Publication: |
493/413 |
International
Class: |
B31F 1/00 20060101
B31F001/00 |
Claims
1. An apparatus for converting a rolled web into a fan-fold web
comprising: a creasing station capable of receiving said web at a
feed rate wherein said web comprises labels thereon and wherein
said creasing station comprises: a first die roller wherein said
first die roller comprises a first blade and a first cushion; a
second die roller wherein said second die roller comprises a second
blade and a second cushion; a coupling mechanism synchronizing
rotation of said first die roller and said second die roller such
that said first blade engages said second cushion and said second
blade engages first cushion during one said rotation; a reader
capable of determining a location of a gap between said labels; a
controller capable of receiving said location of said gap from said
reader; and a drive mechanism in communication with said controller
wherein a rotation rate of said first die roller is adjusted
independent of said feed rate such that said first blade and said
second cushion engage at said gap thereby forming a crease at said
gap.
2. The apparatus for converting a rolled web into a fan-fold web of
claim 1 wherein said drive mechanism is a servo motor.
3. The apparatus for converting a rolled web into a fan-fold web of
claim 1 wherein said reader is an optical reader.
4. The apparatus for converting a rolled web into a fan-fold web of
claim 1 further comprising a splicer.
5. The apparatus for converting a rolled web into a fan-fold web of
claim 1 further comprising a bin for collecting said fan-fold
web.
6. The apparatus for converting a rolled web into a fan-fold web of
claim 1 wherein said first die roller and said second die roller
are separated by a distance.
7. The apparatus for converting a rolled web into a fan-fold web of
claim 1 wherein said coupling mechanism comprises gears.
8. The apparatus for converting a rolled web into a fan-fold web of
claim 1 further comprising a finishing station.
9. The apparatus for converting a rolled web into a fan-fold web of
claim 1 wherein at least one of said first die roller and said
second die roller is cylindrical.
10. A method for converting a rolled web into a fan-folded web
comprising: providing a roll of said web wherein said web comprises
labels thereon with gaps between said labels; passing said roll
through a creasing station at a feed rate wherein said creasing
station comprises: a first die roller wherein said first die roller
comprises a first blade and a first cushion; a second die roller
wherein said second die roller comprises a second blade and a
second cushion; a coupling mechanism synchronizing rotation of said
first die roller and said second die roller such that said first
blade engages said second cushion and said second blade engages
first cushion during one said rotation; a reader capable of
determining a location of a first gap of said gaps; a controller
capable of receiving said location of said first gap from said
reader; and a drive mechanism in communication with said controller
wherein a rotation rate of said first die roller is adjusted
independent of said feed rate such that said first blade and said
second cushion engage at said first gap thereby forming a first
crease at said first gap; rotating said first die roller and said
second die roller until said second blade and said first cushion
engage at a second gap of said gaps thereby forming a second crease
at said second gap wherein said second crease is on an opposite
side of said web from said first crease; and folding said web at
said first crease and said second crease thereby forming said
fan-folded web.
11. The method for converting a rolled web into a fan-folded web of
claim 10 wherein said drive mechanism is a servo motor.
12. The method for converting a rolled web into a fan-folded web of
claim 10 wherein said reader is an optical reader.
13. The method for converting a rolled web into a fan-folded web of
claim 10 further comprising splicing a second web to said web.
14. The method for converting a rolled web into a fan-folded web of
claim 10 further comprising collecting said fan-fold web in a
bin.
15. The method for converting a rolled web into a fan-folded web of
claim 10 wherein said first die roller and said second die roller
are separated by a distance.
16. The method for converting a rolled web into a fan-folded web of
claim 10 wherein said coupling mechanism comprises gears.
17. The method for converting a rolled web into a fan-folded web of
claim 10 further comprising passing said web through a finishing
station.
18. The method for converting a rolled web into a fan-folded web of
claim 10 wherein at least one of said first die roller and said
second die roller is cylindrical.
Description
BACKGROUND
[0001] The present invention is related to an improved method for
forming a fan-folded web of labels, particularly pressure sensitive
labels, with improved registration of the fold relative to the
position of the labels. More particularly, the present invention is
related to an improved method of forming a fan-folded web of labels
wherein the formation of fan-fold creases can be correctly
registered even with perturbations in the motion of the web.
[0002] There has been a long standing need for the formation of
fan-folded arrangements of webs containing labels. Typically, the
webs are formed with labels adhered thereto in a repeating pattern
typically with a fixed frequency. The web is then passed through a
creasing station wherein creases are formed in the web, between
labels, and the web is folded in alternating fashion at the
creases. Typically, perforations have assisted in forming a fold.
Previously webs have been creased or perforated in line
transversely across the web on alternating sides to form folds at
the creases or perforations in alternating directions thereby
allowing the fan-fold labels to be stored and boxed for transport
and subsequent use. Such a web 10 is illustrated in FIG. 1 with
labels 12 and folds 14 being placed in bin 16.
[0003] To ensure the creases, and therefore folds, are correctly
registered between labels the mechanism for transporting the web
through the crease station has been mechanically coupled with die
rolls thereby insuring that any fluctuation in speed of the web,
the length of the labels or the web tension will be in concert with
the rotation of the die rolls. An exemplary teaching of such a
machine is described in U.S. Pat. No. 7,762,939.
[0004] While the in-line machines currently available in the art
have enjoyed much success in commerce they still have certain
deficiencies in flexibility which have become accepted.
[0005] In spite of the relative success of web creasing machines
for formation of fan-fold webs the art still has a strong desire
for an improved design which will advance the art of fan-folding
webs of material, particularly, webs comprising labels such as
self-adhesive or pressure-adhesive labels.
SUMMARY
[0006] It is an object of the invention to provide an improved
method for forming a fan-folded web.
[0007] It is another object of the invention to provide a creasing
station which creases a web on alternating faces at a fixed
separation with minimal error due to variations in web speed or web
conditions or label conditions.
[0008] A particular feature of the invention is the ability to
decouple the rate of creasing from the web movement thereby
allowing for alteration of the position of the crease in the event
of a perturbation in the web or web feed.
[0009] These and other embodiments, as will be realized, are
provided in an apparatus for converting a rolled web into a
fan-fold web. The apparatus has a creasing station capable of
receiving the web at a feed rate. The web comprises labels thereon.
The creasing station has a first die roller, wherein the first die
roller comprises a first blade and a first cushion, and a second
die roller, wherein said second die roller comprises a second blade
and a second cushion. A coupling mechanism synchronizes rotation of
the first die roller and the second die roller such that the first
blade engages the second cushion and the second blade engages the
first cushion during one each rotation. A reader is provided which
is capable of determining the location of a gap between the labels.
A controller is provided which is capable of receiving the location
of the gap from said reader and communication with a drive
mechanism to adjust the rotation rate of said first die roller,
independent of the feed rate, such that the first blade and the
second cushion engage at the gap thereby forming a crease at the
gap.
[0010] Yet another embodiment is provided in a method for
converting a rolled web into a fan-folded web. The method
includes:
providing a roll of web wherein the web comprises labels thereon
with gaps between the labels; passing the roll through a creasing
station at a feed rate wherein the creasing station comprises: a
first die roller wherein the first die roller comprises a first
blade and a first cushion; a second die roller wherein the second
die roller comprises a second blade and a second cushion; a
coupling mechanism synchronizing rotation of the first die roller
and the second die roller such that the first blade engages the
second cushion and the second blade engages the first cushion
during one rotation; a reader capable of determining a location of
a first gap; a controller capable of receiving the location of the
first gap from the reader; and a drive mechanism in communication
with the controller wherein a rotation rate of the first die roller
is adjusted independent of the feed rate such that the first blade
and the second cushion engage at the first gap thereby forming a
first crease at the first gap; rotating the first die roller and
the second die roller until the second blade and the first cushion
engage at a second gap of the gaps thereby forming a second crease
at the second gap wherein the second crease is on an opposite side
of the web from the first crease; and folding the web at the first
crease and the second crease thereby forming the fan-folded
web.
BRIEF DESCRIPTION OF FIGURES
[0011] FIG. 1 is a perspective schematic view of a fan-folded web
with labels thereon.
[0012] FIG. 2 is a schematic side view of an embodiment of the
invention.
[0013] FIG. 3 is a schematic partial view of an embodiment of the
invention.
[0014] FIG. 4 is a schematic cross-sectional view of an embodiment
of the invention.
DETAILED DESCRIPTION
[0015] In accordance with this invention, it has been found that
fan-folded webs can be creased off line but that many problems must
be addressed. If the web slips, stretches or otherwise loses
registration with the die rolls there is a high likelihood that
some labels will be damaged. Furthermore, if the size, spacing or
periodicity of the labels changes even slightly the registration
between the die rolls and web transport must be altered such as by
changing gear ratios or the like. Any inaccuracy in the periodicity
of the creases with respect to the periodicity of the labels will
eventually lead to a misregistration of the creases.
[0016] The present invention is related to an improved off line
creasing station for the formation of a fan-folded web and an
improved method of forming a fan-folded web which overcomes the
problems discussed above. More specifically, the present invention
is related to a crease station wherein the rate of rotation of the
die rolls is driven independently from the rate of web movement
using optical characterization of label placement on the web for
controlling the die roll rotation rate.
[0017] The invention will be described with reference to the
figures which form an integral, non-limiting component of the
disclosure. Throughout the specification similar elements will be
numbered accordingly.
[0018] A schematic view of an embodiment of the invention is
illustrated in FIG. 2. In FIG. 2, a roll, 20, of web, 22, on a
mandrel, 24, is converted to a fan-fold stack, 26, of web in a bin,
28. A crease station, 30, which will be described more fully below,
creases the web between labels and on alternate sides. The folds,
31, occur at the creases. An optical reader, 32, determines the
location of gaps between labels and relays the spacing to a
controller, 34, through a communication link, 33, which may be
electrical, optical or wireless communication. The controller
regulates the rotation rate of roller dies within the crease
station thereby insuring that the crease is between labels and
appropriately spaced. A splicer, 36, allows sequential rolls to be
joined thereby forming a near-continuous operation. The splicer may
also allow sections of a roll to be removed and either end thereof
rejoined to remove areas with defective labels, defective web or
both. An optional, but preferred, finishing station, 38, may
provide an inspection function to insure defective sections do not
reach the bin. The finishing station may have a splicer in some
instances thereby allowing removal of defects. Nip rollers, 40 and
41, draw the web through the various stations with tension provided
by resistance, preferably, at the mandrel, 24. A folder, 39,
persuades the web to fold at the crease. The folder may be
mechanical, such as brushes or rollers, or may persuade the web to
fold by air pressure or the like. Various rollers, guides,
compression wheels and the like would be incorporated throughout as
would be well known to one of ordinary skill in the art and further
elaboration of the details associated with web control are not
repeated herein.
[0019] A partial view of an embodiment of the invention is
illustrated in FIG. 3 wherein illustrated schematically is a
complementary pair of die rollers, 44 and 45, which turn in
opposite directions in concert. Each die roller has a cushion, 46,
and a blade, 48, wherein a blade from one die roller engages a
cushion of the other die roller to form a crease in the web passing
there between. In FIG. 3 the cushion, 46, of the top die roller,
44, is visible and the blade, 48, of the bottom roller, 45, is
visible with the complementary component of each die roller being
obscured from view. A coupling mechanism, 43, synchronizes the die
rollers in counter rotating relationship wherein the rotation is
properly timed such that the blade of one die roller and cushion of
the other die roller arrive at the web in mating relationship. A
preferred coupling mechanism comprising mating meshed gears, 50,
with a common diameter insures the die rollers remain in
counter-rotating synchronization. It is preferable that the die
rollers rotate such that the face of the roller is moving in the
same direction as the web.
[0020] A die roller drive, 52, which is preferably a servo motor,
drives one die roller with the other rotating in synchronized
fashion as described above. For the purposes of illustration the
upper die roller, 44, is a master roller which is coupled to the
die roller drive and the lower die roller, 45, is a slave roller
which follows the master roller through the coupling mechanism. The
rate of rotation of the die rollers is controlled by the
controller, 34, based on a signal from the optical reader, 32. A
particular feature of the present invention is that the rotation
rate of the die rollers is independent of the feed rate of the web.
The optical reader determines the exact location of spacing between
the labels and, based on the determined location, the controller
manipulates the rotation rate of the die rollers, through the die
roller drive, to insure that the blade and cushion arrive at the
proper location on the web to insure a crease is properly located
between labels. In the event of a perturbation in the web
transport, such as a slippage in the web relative to the web drive
mechanism, the rotational rate of the die rollers can be adjusted
by the controller based on a change in the determined position of
the gap between labels as recognized by the optical sensor.
Therefore, the crease can be correctly placed without regard for
perturbations in the movement of the web. The ability to compensate
for web movement perturbations provides a significant advantage
over the prior art since a perturbation in a mechanically coupled
creaser would necessarily cause a misregistration of the crease
thereby ultimately leading to a defective fan-folded web. Various
bearings, fittings, couplings and the like are not illustrated
since these are not particularly limiting and many variations and
arrangements could be easily arrived at based on standard
engineering practice.
[0021] The optical sensor is not limiting with the proviso that the
optical sensor is capable of distinguishing the gap on the web
between labels without regard for design or color.
[0022] An embodiment of the invention will be described with
reference to FIG. 4 wherein illustrated is a pair of complementary
die rollers, in creasing orientation, taken in cross-section. In
FIG. 4, an upper die roller, 44, and a lower die roller, 45, are
rotationally coupled to have the same rotational rate in opposing
direction as realized from previous discussion. Each die roller has
a blade, 48, which is secured to the die roller such as by threaded
members, 49. On the opposite side of the die roller a cushion, 46,
is provided in a channel, 47, of the die roller. The die rollers
preferably rotate in the direction of arrows, 53, and the web moves
in the direction of arrow, 55. Twice during each full rotation of
the die rollers a blade of one die roller and a cushion of the
other die roller meet with the web there between wherein the blade
presses the web against the cushion thereby forming a crease, 51.
The rollers are separated by a distance sufficient for the web to
pass between the rollers, between creases, without contacting
either roller.
[0023] Discounting adjustments due to perturbations, the separation
of creases is defined relative to the diameter, D, of the die
rollers. Creases on a common face are separated by N1 which is the
circumference of the die roller, or D.pi.. Adjacent creases on
opposing faces are separated by N2 which is half of the
circumference or D.pi./2. While demonstrated as a cylindrical die
roller the die rollers could be other shapes as long as the blade
and cushion track a circular path with the desired diameter.
[0024] The fan-folded webs are typically used in newspaper labeling
operations at very high speeds. It is not uncommon for over 1000
labels to be applied per minute. This high rate of speed requires a
web with a sufficient structural strength to avoid tears. It is
therefore preferable to avoid perforations when forming the
creases.
[0025] A particular advantage of the instant invention is the
elimination of the necessity for a high level of web tension. With
prior art, mechanically coupled, creasers the web must be
maintained in relatively high tension to insure that the movement
through various rollers and drives is consistent with minimal
slippage. With the present invention the determination of the gap
between labels is accomplished just prior to the creaser thereby
eliminating the need for a high degree of web tension. There must
be sufficient tension to avoid buckling between the optical sensor
and creasing but this is easily accomplished with relatively low
web tension.
[0026] While not limited thereto, the primary commercial
application of the creaser is for forming fan fold webs which are
narrow, such as about 5.08 to about 10.16 cm (about 2 to about 4
inches), with labels that are approximately 7.62 cm (3 inches) in
length. The gap between labels is intentionally kept to a minimum
to minimize the total length of the web with a gap of about 3.175
mm (0.125 inches) being most common. The length of each ply of
fan-folded web is not particularly limited by the invention but a
length of about 31.75 cm (12.5 inches) is most preferred since this
is a standard size employed by most modern label application
machines. The width of the web, the size of the labels, the gap
between labels, etc. can be easily adjusted and the creaser of the
present invention can be easily adjusted to accommodate from very
small to very large samples.
[0027] Throughout the specification positional terms such as upper
and lower are for convenience of discussion and may have no basis
or relevance in actual practice.
[0028] The web is not particularly limited herein. In practice, a
laminated web with a release layer is most commonly employed. The
label typically has a pressure-sensitive adhesive coating thereon.
In use the labels are removed from the web and applied to a
surface, such as a newspaper, and the web is discarded. The manner
in which the web is formed, the manner in which the labels are
applied to the web and the manner in which the labels are removed
from the web for application is not particularly limited herein and
the inventive creaser, and method of creasing, is intended to
coordinate with existing and future equipment before and after the
creasing operation.
[0029] The invention has been described with reference to the
preferred embodiments without limit thereto. One of skill in the
art would realize additional embodiments and improvements which are
not specifically set forth herein but which are within the metes
and bounds of the claims appended hereto.
* * * * *